Mastic tile



Patented June 19, 1945 MASTIO TILE MartinK.Bare,Lancaater,Pa.,assignortoArmstrong Cork Company, Lancaster, Pa., a corporation of Pennsylvania No Drawing. Application January 9, 1941,

Serial No. 373,807

16 Claims. (01. 260-26) This invention relates to composition tile commonly'designated by the term mastic tile."

Polymers of coumarone, indene and related resins have been incorporated with plasticizers and fillers to produce mastic floor and wall tiling. As previously compounded, however, such tiling is not especially resistant to oils and greases. This particular disadvantage precludes the use of such tile in restaurants, garages, andfllling stations. This lack of grease resistance has been recognized and has led to numerous attempts to remedy it. For example, as disclosed in United States Patent 2,145,648, issued to Charles E. Fawkes et al., the patentees overcome the disadvantage by substitution of the resin with cellu lose ethers.

It has now been found that a mastic tile of improved oil and grease resistance can be produced from the coumarcne, indene, styrene and related resins having a molecular weight of at least about 1,000 by compounding such resins with a soft resin 01' the alkyd type, such polymeric condensation products supplanting part of the plasticizer content that would normally be used with the hard resin. It has been found, however, that the improved oil and grease resistance is obtained by incorporating alkyd resins formed by the reaction of a polyhydric alcohol or their polyhydric ethers, such as glycerol, ethylene glycol, diethylene glycol, triethylene glycol, diglycerol, glycerol ethers, etc., with dibasic acids, such as phthaiic acid, succinic acid, malonic acid, methyl succinic acid, sebacic acid, related aromatic and aliphatic dicarboxylic acids and their homologues, are used. The preferred alkyds, because of .their optimum degree of softness and their present commercial availability and low cost, are the reaction products of the glycols and glycol ethers having at least three carbon atoms, especially with phthalic acid.

In the formulation of the composition tile, from 25% to 35% of binder composed of the hard resin, the soft alkyd, and plasticizers, is compounded with from about 65% to 75% of fillers, including inert inorganic pulverulent or fibrous materials and, if desired, pigments.

The hard resin constitutes the major portion have a. molecular weight of at least about 1,000, the molecular weight being based upon viscosity measurements. The soft alkyd resin of the type described above constitutes from 10% to 25% of the binder andiunctions as a softening constituent of the tile, improving the toughness thereof, and, as stated above, improving the oil and grease resistance of the tile and at the same time maintaining good resistance to saponiilcation by alkalies. This soft-resin, though softening the binder, should not be considered to be a plasticizer because the hard resins have only limited compatibility withit. However, by virtue of its softness, it is possible to use much less plasticizer in this type 01' formulation than would be employed according to previous formulae. In addition to the hard resin and the soft alkyd, the binder contains from about 8% to 25% of a plasticirer, such as dibutyl phthalate, tricresyl phosphate, methyl abietate, hydrogenated methyl abietate, ethyl abietate, hydrogenated ethyl abietate, etc. Mineral oil up to 5% by weight of the binder may be added to aid in obtaining the limited compatibility necessary in the binder to limit the penetrability of the finished tile.

The fillers employed are preferably inert, inorganic pulverized materials, such as clay, or fibrous materials such as asbestos. Serpentine, talc, and whiting are additional examples of filling materials that are suitable- Pigments, such as titanium dioxide, ochre, carbon black, lead chromate, Prussian blue, etc., may be employed in any desired amount to impart color to the tile.

In compounding the tile, the several ingredients are added in any order to a jacketed doughtype mixer. Though not necessary, it is preferred to melt the alkyd before charging it into the mixer. Steam under to pounds per square inch gauge pressure is admitted into the jacket of the mixer and the mixingis carried on for 15 to 30 minutes. Thereupon, the mixer is given a short working upon heated masticating rolls. The mass coming from the masticating rolls iscut into blankets, folded, and passed through a cold calender almost to gauge, then cooled in a water bath, and sent through a second cold calender to exact gauge. If desired, the sheeted mass may be waxed or lacquered to improve the surface finish thereof. The sheeted composition is then passed on a belt through a cooling chamber and then cut to size.

Coumu'oneresin (mo. wt.

Diethylene glycol succimite... Glycerol Thefollowing representative examples in which the numbers refer to per cent by weight are illustrative of the invention:

Example No.

Polystyrene (mo. wt. 25,-

Ot'll to 40,000)

Polyindoue..

Dieiiylsne glycol phthal- 'lrlathylene glycol plithsi- Hydrogenated methyl abietste Dibutyl phthalate eral oil The composition binder of the invention is of light color so that-it is easily pigmented to any desired shade. Besides imparting the improved .oil and grease resistance, the soft alkyd resin imparts a remarkable toughness so that the tile y can be made of greater hardness without having the undesirable brittleness that necessarily ac companied any increase in hardness of this type of composition tile heretofore produced. This .increased toughness obviously results in much The greater hardness permits usage where greater loads willless breakage in shipping and use.

' materials indefinitely stated proportions, the Y description is intended to be merely illustrative.

It is obvious that various modifications may be made without departingfrom the spirit of the invention and. it late be understood that this invention is limited only by the appended claims.

' I claim:

1. A preformed, composition tile comprising from about 65% to about 75% by weightof filler,

and from about 35% to about 25% by weight of binder, said binder essentially consisting of from about 55% to about 80% by weight of a hard resin having a molecular weight of at least 1,000 selected from the group consisting of polymers or coumarone, indene, and styrene; from about 10% to about 25% by weight. of an alkyd resin consisting of a polymeric condensation product of a polyhydric alcohol and an organic dicarboxylic acid: and from about 8% to about'25% game" consistin'gotapolymerio oondensationprcduot oi a polyhydric alcohol and an organic dicar-' boxylio acid; and from about 8% to about 25% by weight oi a plasticizer for saidhard resin and said condensation product.

3. A preformed, composition tile comprising from about 65% to about 75% by weight of filler, and'from about 85% to about 25% byweight oi binder, said binder including from about to about 80% by weight 01' a hard resin'having a molecular weight of at least 1,000 selected from the group consisting of polymers of coumarone, indene, and styrene; from about 10% to about 25% by weight of an alkyd resin consisting of a polymeric condensation product of a glycol with an organic dicarboxylicacid; and from about 8% to about 25% by weight of a plasticizer. 4. A preformed, composition tile comprising filler and binder, said binder including from about 55% .to about 80% by weight of a hard resin having a molecular weight of at least 1,000 selected from the group consisting of polymers of coumarone, indene, and styrene; from about I 10% to about 25% by weight of an alkyd resin consisting of a polymeric condensation product ofa glycol with an organic dicarboxylic acid; and from about 8% to about 25% by weight of a plasticizer.

5. A preformed, composition tile comprising from about to about 75% by weight oi a filler, and from about 35% to about 25% by weight of binder, said binder including from about 55% to about 80% by weight of a hard resin having a molecular weight of at least 1,000 selected from the group consisting of polymers of coumarone,-indene, and styrene; from about 10% to about 25% by weight of an alkyd resin consisting of a polymeric condensation product of a glycol with an organic dicarboxylic acid;

and from about 8% to about 25% by weight of a plasticizer, said plasticizer including a mineral oil in an amount not of said binder.

6. A preformed, composition tile comprising filler and binder, said binder including from .about 55% to about 80% by weight of a hard resin having a molecular weight of at least 1,000 selected from the group consisting of polymers I of coumarone, indene, and styrene; from about 10% to about 25% by weight of an. alkyd resin consisting of a polymeric condensation product of a'glycol with an organic dicarboxylic acid; and from about 8% to about 25% by weight 0! a plasticizer, said plasticizer including a mineral oil in an amount not greater than 5% by weight of said binder.

by weight of a plasticizer for'said hard resin and said condensation product.

2.. A preformed, composition tile comprising iiller and binder, said binder including from by weight of a plasticizer.

7. A preformed, composition tile comprising filler and binder, said binder including from about 55% to about by weight of a hard resin having a molecular weight of at least about 1,000 selected from the group consisting of polymers, coimiarone, indene, and styrene; from about 10% to about 25% by weight of diethylene glycol phthalate resin: from about 8% to about 25% by weightof a plasticizer.

8. A preformed, composition tile comprising filler and binder, said binder including from about 55% to about 80%-by weight 01 a hard resin having a molecular weight of at least about 1,000 selected'from thegroup consistingol poiymersof coumarone, indene, and styrene: from about 10% to about 25% by weight of triethylene glycol phthalate resin; from about 8% to about 25% 9. A preformed, composition comprising greater than 5% by weight and from about 35% to about 25% by weight 01" filler and binder, said binder including from about 55% to about 80% by weight or a hard coumarone resin having a molecular weight of at least about 1,000; from about to about 25% by weight of an alkyd resin consisting of a polymeric condensation product of a glycol with an organic dicarboxylic acid; and from about 8% to about 25% by weight of a plasticizer.

10. A preformed, composition tile comprising filler and binder, said binder including from about 55% to about 80% by weight of a hard polystyrene resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of an alkyd resin consisting of apolymeric condensation product of a glycol with an organic dicarboxylic acid; and from about 8% to about 25% by weight of a plasticizer.

11. A preformed, composition tile comprising from about 65% to about 75% by weight of filler, and from about 35% to about 25% by weight of binder, said binder comprising a hard coumarone resin having a molecular weight of at least about 1,000, from about 10% to about 25% by weight of diethylene glycol phthalate resin; and from about 8% to about 25% by weight of a plasticizer.

12. A preformed, composition tile comprising from about 65% to about 75% by weight of filler, and from about 35% to about 25% by weight of binder, said binder comprising from about 55% to about 80% by weight of a hard coumarone resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of tri ethylene glycol phthalate resin; and from about 8% to about 25% by weightof a plasticizer.

13. A preformed, composition tile comprising from about 65% to about 75% by weight of filler,

binder, said binder including from about 55% to about 80% by weight of a hard coumarone resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of diethylene glycol phthalate resin; and from about 8% to about 25% by weight of hydrogenated methyl abietate.

14. A preformed, composition tile comprising from about 65% to about 75% by weight of filler, and from about to about 25% by weight of binder, said binder including from about to about 80% by weight of a hard polystyrene resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of triethylene glycol phthalate resin; and from about 8% to about 25% by weight of hydrogenated methyl abietate.

15. A preformed, composition tile comprising from about to about by weight of filler, and from about 35% to about 25% by weight of binder, said binder including from about 55% to about by weight of a hard polystyrene resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of diethylene glycol phthalate resin; and from about 8% to about 25% by weight of a plasticizer.

16. A preformed, composition tile comprising from about 65% to about 75% by weight of filler, and from about 35% to about 25% by weight of binder, said binder including from about 55% to about 80% by weight of a hard polystyrene resin havin a molecular weight of at least about 1,000; from about 10% to about 25% by weight of diethylene glycol phthalate resin; and from about 8% to about 25% by weight of dibutyl phthalate. MARTIN K. BARE.

CERTIFICATE (1F CORRECTION.

Patent no. 2,578,577 r mm'rnr x. BARE.

It is hereby certified that error appears in the printed specification of the above m mbered patent requiring correction as follows: Page 2, first column, lin 75, claim 2 for 'allcyl' read -allcyd--; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed.and sealed this 18th day of September, A. D.-191i5.

Leslie Frazer First Assistant Commissioner of (seal) Patents and from about 35% to about 25% by weight 01" filler and binder, said binder including from about 55% to about 80% by weight or a hard coumarone resin having a molecular weight of at least about 1,000; from about to about 25% by weight of an alkyd resin consisting of a polymeric condensation product of a glycol with an organic dicarboxylic acid; and from about 8% to about 25% by weight of a plasticizer.

10. A preformed, composition tile comprising filler and binder, said binder including from about 55% to about 80% by weight of a hard polystyrene resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of an alkyd resin consisting of apolymeric condensation product of a glycol with an organic dicarboxylic acid; and from about 8% to about 25% by weight of a plasticizer.

11. A preformed, composition tile comprising from about 65% to about 75% by weight of filler, and from about 35% to about 25% by weight of binder, said binder comprising a hard coumarone resin having a molecular weight of at least about 1,000, from about 10% to about 25% by weight of diethylene glycol phthalate resin; and from about 8% to about 25% by weight of a plasticizer.

12. A preformed, composition tile comprising from about 65% to about 75% by weight of filler, and from about 35% to about 25% by weight of binder, said binder comprising from about 55% to about 80% by weight of a hard coumarone resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of tri ethylene glycol phthalate resin; and from about 8% to about 25% by weightof a plasticizer.

13. A preformed, composition tile comprising from about 65% to about 75% by weight of filler,

binder, said binder including from about 55% to about 80% by weight of a hard coumarone resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of diethylene glycol phthalate resin; and from about 8% to about 25% by weight of hydrogenated methyl abietate.

14. A preformed, composition tile comprising from about 65% to about 75% by weight of filler, and from about to about 25% by weight of binder, said binder including from about to about 80% by weight of a hard polystyrene resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of triethylene glycol phthalate resin; and from about 8% to about 25% by weight of hydrogenated methyl abietate.

15. A preformed, composition tile comprising from about to about by weight of filler, and from about 35% to about 25% by weight of binder, said binder including from about 55% to about by weight of a hard polystyrene resin having a molecular weight of at least about 1,000; from about 10% to about 25% by weight of diethylene glycol phthalate resin; and from about 8% to about 25% by weight of a plasticizer.

16. A preformed, composition tile comprising from about 65% to about 75% by weight of filler, and from about 35% to about 25% by weight of binder, said binder including from about 55% to about 80% by weight of a hard polystyrene resin havin a molecular weight of at least about 1,000; from about 10% to about 25% by weight of diethylene glycol phthalate resin; and from about 8% to about 25% by weight of dibutyl phthalate. MARTIN K. BARE.

CERTIFICATE (1F CORRECTION.

Patent no. 2,578,577 r mm'rnr x. BARE.

It is hereby certified that error appears in the printed specification of the above m mbered patent requiring correction as follows: Page 2, first column, lin 75, claim 2 for 'allcyl' read -allcyd--; and that the said Letters Patent should be read with this correction therein that the same may conform to the record of the case in the Patent Office.

Signed.and sealed this 18th day of September, A. D.-191i5.

Leslie Frazer First Assistant Commissioner of (seal) Patents 

